Abstract: An exothermic welding jig, molds for the jig, and a method of forming and manipulating the mold parts is disclosed. Upper and lower mold parts are included with a crucible fitted on and clamped to the upper mold part. The upper mold part and crucible may be moved as a unit to open and close the mold and also inverted when open for cleaning and inspection. The crucible can quickly be removed or snapped in place for mold or crucible change out. The jig will fit in cramped quarters and has a handle which may be used as a cane or supporting device. A toggle opens and closes the mold set and will hold the molds at any position where released. A mold system with diagonal sleeving makes it easier to form X-connections and other connections in tight or restrictive locations. The method includes the attachment and manipulative steps.

Abstract: An exothermic welding apparatus and method uses a crucible which can be used with a variety of exothermic weld metal material volumes to produce welds of different sizes while maintaining the desired diameter to height ratio for each volume of exothermic material. In one embodiment, the crucible includes a double or two stage cavity. The crucible includes a somewhat smaller lower stage which reduces the diameter for smaller volumes. This lower stage may have two disk seats to isolate the two stages from the tap hole. A disk seat is provided for a larger disk between the two stages. The crucible may include a volume of exothermic material in the smaller lower chamber, the larger upper chamber, or a combination of both. In a triple stage embodiment, a wider variety of exothermic material volumes or masses may be accommodated, all while maintaining the desired diameter to height ratio for each charge. Although the desired ratio is approximately one, the ratio range should be maintained from about 0.5 to about 1.